Manufacture by electrodeposition



Feb. 6, 1951 G. ROSENQVIST 2,540,175

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MANUFACTURE BYELECTRODEPOSITION Filed Feb. 11, 1947 14 Sheets-Sheet 12 INVENTOR. 6210720117905 62220252 Feb. 6, 1951 G. ROSENQVIST 2,540,175

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MANUFACTURE BY ELECTRODEPOSITION Filed Feb. 11, 1947 14 Sheos-5heet 14 Patented Feb. 6, 1951 UNITED STATES PATENT OFFICE MANUFACTURE BY ELECTRODEPOSITION Gunnar Rosenqvist, Calumet, Mich.

Application February 11, 1947, Serial N 0. 727,793 7 v This invention relates to the manufacture of metal articles by electrolytic deposition and is a continuation in part of my applications Ser. No. 460,220, filed September 30, 1942, and Ser. No. 443,288, filed May 16, 1942, now abandoned.

A primary object of my invention is to provide for the utilization selectively of either or both of two methods of mechanically displacing or working metal particles as they are deposited electrolytically, to afford two kinds of internal structure in the electrodeposited metal. These two methods differ fundamentally from each other.

One method consists of moving surface particles of the cathode, or electrodeposited metal, in

directions laterally of the cathode surface to positions loosely superimposed on the outside of the surrounding cathode surface, and is effected by abrading, grinding,- or otherwise frictionally working the deposited metal. The particles as thus displaced have little or no bond with the cathode surface and, when covered over by further electrodeposition, form laminations within the structure enclosing plating solution which expands on subsequent heating to form pockets within the metal structure.

The other method consists of moving metal particles from one position to another entirely within the cathode surface, and is effected by pressing on the surface particles of the cathode only in directions normal to the surface of working contact thereby avoiding frictional abrasion. accordance with this method, there being no loosely superimposed particles on topof the oathode surface, that surface win; he built up by further electrodeposition. intoa sound structure that has no laminations or pockets.

, These methods are performed mechanically by the use of. atool. and. thus I have found that the use of a,- tool permits achoice of workingaction's and that by changing the participation of friction forces during working contact different internal. structures in the. electrodepositedmetal may be obtained for differentdesired purposes. In commercial adaptations of my methods the tool has a working face which is small in comparison with. the area of the; cathode surface and in order that all areas of the surface may be worked by the use of such a tool, it is necessary that-the tool traverse the surface, as well as press against it. Despite" such traverse motion I assure selectivity of the working actions above referred to.. Thus, to avoid. any frictional sliding between tool and the cathode. surface during: working 30 Claims. (G1. 204-9) 2 a cathode surface which moves intermittently and is held motionless during contact of the tool with the surface of the deposited metal and another embodiment employs a cathode surface which, although moving continuously, is virtually motionless during such contact because the tool breaks contact with the metal surface immediately upon striking it so that there is no opportunity for lateral relative movement during contact. Where, on the contrary, I desire frictional sliding between the tool and the cathode surface in selected areas I provide a further embodiment in which such sliding occurs but in which it is controlled for the purposes intended.

My further objects are to improve generally on known methods of manufacture by electrodeposition and on the construction of machines of this character as well as to provide metal articles of novel characteristics as will appear.

By my invention I believe I have achieved for the first time electrolytically refined copper cathodes of commercially satisfactory internal drawstock for seamless copper tubing; and the quality of my electrolytic cathodes is not only satisfactory but far superior to anything yet put on the market due to its freedom from oxide and its perfectly sound internal structure.

In the drawings- 4 Fig. 1 is a side elevation view of the inlet end of a machine embodying my invention, shown as manufacturing tubing continuously. v

Fig. la.- is aside elevation view of thedelivery end of the machine, Fig. 1 and 1a together showing the complete machine. a

Figs. 2 and 2a are plan views corresponding to Figs. 1' and 1a.

Figs. 3 and 3a show one of the mandrels and the tubing thereon in process of manufacture.

Fig. 4 is a vertical section along the lines 4'"='4 of Fig. 5.-

Fig'. 4a is a vertical section through one of the clutches.-

Fig. 5 is a vertical section along the lines 5-*-5 of Fig. 2a.

Fig. 6 is a detail elevation view of a hammer and associated parts, partly in section.

7 is a detail vertical section along the line Fig. 9 is a detail vertical section of a novel type Fig. 13 is a vertical section of a modification I of the machine.

Fig. 14 is a vertical section taken along I4l4 of Fig. 13.

Fig. 15 is an enlarged vertical section of a pressure applying element or hammer.

Fig. 15a is a view similar to Fig. 15 showing the pressure element in pressing position against the surface of the metal sheet.

Fig. 16 is a face view of the pressure elements.

Fig. 17 is a vertical section on an enlarged scale taken on the line ll-I'I of Fig. 13.

Fig. 18 is a vertical section on the line l8l8 of Fig. 17.

Fig. 19 is a side elevation view of the inlet end of a further embodiment of my machine having certain pressure elements which are caused to dwell against the surface of the metal for a purpose which will appear. 2

Fig. 19a is a side elevation view of the delivery end of that machineFigs. 19 and 1911 together showing the complete machine.

i the line Figs. 20 and 20a are plan views corresponding to Figs. 19 and 19a.

Fig.21 is a side elevation view corresponding to Fig. 19 with parts omitted.

Figs. 22, 23 and 24 are vertical sections through a mandrel and tubing showing progressive stages of the manufacture of the tubing. 1

' Fig. 25 is a detail vertical section of a portion of the tubing showing a clutch.

Fig. 26 is a vertical section on line 25-26 of Fig. 19a.

Fig. 2'? is a perspective view of the pattern mounted on the end of the mandrel.

Fig. 28 is a longitudinal section of one form of tubing, and

Fig. 29 is a vertical section taken on line 2929 of Fig. 28.

Referring to Figs. 1, la, 2 and 2a the machine the electrolytic deposition of metal-from electrolyte within the tank 2. The electrolyte supply is stored in tank 4 (Fig. 111) from which it'is withdrawn by pump I99 driven by motor I92 pumping the solution from storage tank 4 through pipe H34, manifold I96 (Fig. 4) branch pipes I 98 leading to risers 206 which terminate in the outlets 20! (Fig. 10) emptying into the tank 2.

Also within the tank is a supply of copper tank, another row 82) extending along'the other wall and a row extending down the middle of the tank. The perforate side walls of each basket slope downwardly and terminate short of the bottom members 3 (Fig. .4) .whichiin turn slope downwardly to the outlet channel'fi so that loosely in enlarged holes 22!.

the metal scrap anode works its way beneath the mandrels (9 which extend between adjacent rows of baskets as indicated in Fig. 4. The anode sludge collects as a top layer on the free surface between the baskets and being too heavy to rise it does not contaminate the tubing. It is removed periodically by sludge removing rods 225 which lie on the top surface of the anode and are mounted on bent wires 225 whose ends 221 fit Each rod 226 is pivoted to crank 228 at the right hand end of the machine (Fig. 5) which has its upper end projecting into the path of hooks 229 and 238 secured to a carriage 54, (Figs. 1 and 1a) to be referred to. A reciprocating motion which is imparted to the carriage thus periodically shifts the sludge rods to stir the sludge and cause wires 225 to open up small channels through the anode permitting sludge particles to escape through drains 284 to return pipes 206 and thence back "to tank 4 where the valuable metals are 'recovered. To free the drains 2M periodically rods 2M are provided within the tubes 29 3a which may be reciprocated manually when desired.

Electroplating current from a source not shown is'conducted to the anode 6 by conductors H (Fig. 4) submerged therein and connected to leads 13 which extend to rails 63 (Figs. 1 and la) to be described, extending lengthwise of tank 2 and also functioning as bus bars. The brush I4 (Fig. 5), connected to the other side of the power source, contacts the external surface of the tubing 12, to render it and each mandrel l9, cathodic. 1

A the mandrel enter the tank it is contacted by rods 9 (Fig. 1) disposed on opposite sides of the mandrel as shown in Fig. 2. The rods are electrically connected to the brush l4 contacting the tubing at the outlet end of the machine. The rods 9 are thus of the same polarity as the brush. The portion of the mandrel contacting these rods isthus in efiect anodic with reference to the rods 9 with the result that any plating in the vicinity of the entrance end of the mandrels takes place on the rods 9 rather than on the mandrels. This assures against plating on that portion of the mandrel within the entrance packing. To enhance this effect I place the rods in a compartment 9a so they are partitioned from the main 'body of the tank, the electrolyte communicating through a small opening in the partition.

In operation, the mandrels l0 supported on bearings 15 are advanced to the right to and through tank 2 and simultaneously they are rotated on their own axes. Upon reaching the inner limit of their advancing stroke they are retracted. For this longitudinal movement,jthe mandrels are supported at their outer ends on a common carriage M which is advanced and retracted by feed screws 16 and it connected together by sprocket chain 20. Advance of the mandrels is efiected by motor 28 suitably connected through chain 39 and clutch 36 to feed screw lS-the motor being driven from a source of current connected to it through switch 30, one terminal of which is carried on lever 26. Retraction of the mandrels is efiected by motor 22 connected by chain 24 to feed screw l8-motor 22 being driven from a source of power completed through switch 25, one terminal of which is also carried on pivoted starting lever 25. The carriage I4 is shown about three-fourths retracted in Figs. 1 and 2. When it has been completely .retracted to position adjacent the chain 20,- lever 26 is pushed inwardly toopen Switch 25, thereby stopping retracting motor 22 and closing switch :30 to start motor 28, and also engaging clutch 36. thereby completing the drive to screws I6 and I8 to start the carriage on itsadvancing movement. The mandrels are withdrawn comparatively quickly, in a matter of a few minutes, whereas the advancing time takes a matter or hours, as will be understood in the art.

Power to rotate the mandrels on their axes is :derived frommotor 40 connected by belt 42 to worm and worm gearing, not shown, within the housing of carriage I4.

-.-=1-As the .metal is deposited on the mandrels, which are thus simultaneously advanced and rotated, the metal is subjected to the constant working action of the vertically reciprocating tools or hammers 60 (Fig. 4). These hammers, which there are anumber, aredisposed at intervals along each mandrel above and in ver- -tical alignment with its axis and as they are opposite to the direction of advance of the man- -drels, by linkage l0 and I2, the link 12 terminating in a hook I5 riding on belt I8 having three studs 80 which successively engage hook l6 and -pull it and the hammer carriage slowly to the left -;until the stud 80 disengages latch I6 when spring HM moves the carriage rapidly to the right to its starting position. Belt 78 is advanced by motor 434 connected through gear reducer 86 and belt 88 .to pulley 89 fixed on shaft 96 to which pulley 98a,

receiving belt I8, is also fixed.

To efiect vertical reciprocation of the hammers which thus traverse the mandrels axially, each hammer lifl depends from a crankl I9 protruding from rock shaft I02, each shaft being supported in three bearings 504, I05 and I08 (Fig. 4) and carrying a pair of cranks I III which support a pair of hammers, one for each mandrel. Rocking movement is imparted to each shaft I02 by a crank I00 (Fig. '7) secured to the shaft and carrying a ball follower 98 pressed against hexagjonal cam 96 by spring I2iia extending between "the bar 52 and a crank 12% (Fig. 8) protruding from the rock shaft )2. Cam shaft 94 extends the full length of hammer carriage 64 and carries a-hexagonal cam 96 for eachpairof hammers. {The shaft is rotated by; belt 32 (Figs. 4 and 5) driven by motor 9 I. The hexagonal earns 96 are set indifferent positions onshaft 94 so that the hammers do, not, act simultaneously. This minimizes vibration and it also saves power particularly where there are more than two mandrels and a correspondingly large number of hammers. The. cam shaft and the cam followers coordiare made of a-r'ubber-like material tightly embracing the shaft and in turn embraced by supports [01; thus the rubber-like material yields to permit rock-ing of the shaft and the need for" an oil lubricant is obviated.

The hammers, being made of metal, are-elece trically conducting. To minimize electroplating: on their submerged portions they are encased in insulating material BI (Fig. 6) leaving only the end 63 exposed and that'end portion is made of a metal to which plating metal poorly adheres (i. e. for copper, stainless steel) and is convexed so that any adhering metal will tend to fall oif.

As stated above it is one of the primary objects of my invention to provide method of and apparatus for efi'ecting the hammering in which relative lateral motion between the hammer and the deposited metal is avoided. Thus (Fig. 6), it will be noted that when follower 98 is on the lowest portion of cam 98 the tip'63 of the hammer does not contact the mandrel or the metal deposited thereon but is displaced therefrom a substantial distance. To effect the hammering I provide a yielding connection between the cam follower and the hammer and utilize the momentum of the rapidly reciprocating hammer to carry it-into impact with the metal on the man'- drel. The yielding connection comprises the rubber tubing II4 connected at its upper end to the which are independent of each other, namely.- ;first striking the metal on the cathode, second,

immediately breaking contact with the metal. through the contraction of the rubber and, third, retraction of the hammer for the next;

succeeding stroke by the next rise on the cam 96. Thus the step of breaking contact-is in dependent .of the step of retraction of the- .hammer by thecam. Thereby-I assure against.

any frictional abrasion of the hammer against the metal.

In Figs. Na and III) and No I have shown diagrammatically on greatly enlarged scale the ,working action thus effected. Thereference a designates the hammer or tool approaching the metal I) in a direction substantially perpendicular to the cathode surface 0 as indicated bythe arrow d. On the cathodesurface c are protrusions a formed by crystal growth during the electroating therewith are properly'lubricated and are surface of working contact as indicated by'arrrows f causing the metal particles to flow within the cathode-surface c as indicated by the arrows g. The pressure thus applied continues until the protrusions are flattened and surface 0 is continuous and is entirely level. It will be noted that during this hammering action the hammer c has not moved laterally incontact with the surface c or the protrusions e thereof.v After the hammering has been completed the electrowith that illustrated in Figs. 11m, fly, and 11a, wherein-the tool a. moves laterally in relation to the surface as designated by the arrow h and, by frictional abrasion, moves the protrusions e and displaces first one (Fig. 11.?) and then the other (Fig. 11y) laterally of the cathode surface to positions e where they may be loosely superimposed on the outside of the surrounding cathode surface. After further electrodeposition the completed structure is typified, as shown in Fig. 112, by pockets 7:) containing electrolyte. For certain purposes these pockets have a useful function, as will be hereinafter referred to. The action of the tool a in laterally displacing metal particles where frictional abrasion occurs, as illustrated in Figs. 11m to 112, is not confined to the displacement of protrusions e, as non-protruding portions of the surface are similarly dis placed. These views are merely'diagrammatic and do not, of course, indicate the complex physical changes taking place when pressures are applied to a cathode surface. However, they will serve to illustrate the principle of my invention.

When the hammer mechanism constructed as described with reference to Figs. 6 to 8, inclusive, are employed the working action illustrated 'in Figs; 11a, 11b, and lie, effecting displacement of the metal particles only inside the cathode surface, is obtained and the frictional abrasion of Figs. 11m, 11g and 112, resulting in outside displacement; is avoided. It might be surmised from the fact that the hammer in Figs. '6 to 8 inclusive strikes a cathode surface which is moving continuously in a lateral direction relative to the hammer that of necessity there would be, at least to some degree, lateral relative movement or frictional sliding of the hammer while it is in contact with the cathode. However, in the above described embodiment of 'my invention such is not the case for a number of reasons; first, I guide the hammer for reciprocation in a direction normal to the cathode surface to avoid an' oblique glancing blow which itself would cause lateral relative motion during working contact between the cathode and the hammer; second, the blow which is thus in a normal direction, is with a rebounding stroke so that the hammer breaks contact with the cathode immediately the blow has been struck and the opportunity for lateral relative movement or frictional sliding is virtually non-existent as will be further appreciated from the fact that in my machine the cathode and hammer move laterally relative to each other fonly about one-twentieh of an inch during a complete hammer reciprocation. Finally, the hammer guides permit a very minute lateral play of the hammer so thatthe hammer can move laterally very slightly with the cathode. During striking the pressing force is strong enough to prevent any potential slight true normal direction thereby still causing only inside displacement of the metal particles. This mode of operation is to be contrasted with hammers which after striking are allowed to dwell in contact with the cathode surface and are not retracted therefrom immediately after the striking force is spent. In such a device the pres ing. r meme ee l t ..ith im with th'retiultthat thflirection citric-resultant" working force suddenly deviates from the nor.- mal sufiiciently to overcome frictional resistance and produce frictional sliding, resulting in displacement of metal particles on the outside of the cathode surface.

Where sound metal is desired frictional sliding resulting in outside displacement ofv metal particles cannot be tolerated no matter how minute, because the pockets thereby formed cannot be eliminated as is the case with the pores "or bubbles always present in commercial ingots and which are usually repaired or fused during the heat treatment applied between the working operations. The heat treatment of electrolytic metal having pockets with enclosed plating solution makes the imperfections worse rather than improves them because as explained above such heat treatment is effective merely to increase the vapor pressure of the entrapped plating solution, thus enlarging the pockets. The seriousness of this result can be appreciated from the fact that in electrolytic manufacture the hammering, and thereby the pockets if the ham-'- mering is faulty, is in planes occurring at intervals of about one two-thousandths' of an inch through the cross section of the metal. In the measurements I have made of the pockets made by faulty hammering I have observed many individual pockets of less than one thirty-twothousandths of an inch in diameter which is an indication of the microscopic dimensions of th frictional sliding to be avoided.

A further and important function of the ham mering operation i that it stretches the metal and loosens the tubing from the mandrel so the mandrel may be withdrawn from the tubing, as will be described.

Contributing to the practicable manufacture oftubing continuously on a mandrel of re determined length alternately advanced through the electrolyte and then retracted to starting position, are certain safeguards embodied in my preferred form of machine to obviate electrodeposition of metalon the mandrel during its retraction.

Fig. 4a illustrates a clutch 135 made of annular rings of metal I38 11, I381), and i380 alternating with rubber rings 1 49, all secured together by bolts I42. This clutch fits over the finished tubing I2 on the outlet side of the machine and the internal diameter of the rubber rings M0 is considerably smaller than the external diameter of the tubing. Movement of the tubing to the left relative to clutch I38 is resisted by the action of the inner margins [46 of the rubber rings being squeezed between the tubing l2 and the shoulders I 48 on the insideedges of rings IBM. and i381). The tubing is, however, free to move to the relative to the clutch because in such movement the inner margins I46 of the rubber rings turn to their full line positions shown in Fig. 4a where no wedging occurs. Clutch I36 may move with the tubing between the opposite limits indicated by stop I58 (Fig. 1a) and stop i52 secured to the frame. This arrangement is eifective for a purpose which will appear.

is carried along with it I provide (Fig. 3c) an internal clutch in the form of a rubber ring 50 secured to the end of the mandrel, by boltp52.

The ring is oversized so that when l the mandrel advances to the -right the is squeezed-against 11 tance of one tooth, thereby imparting a rotational movement to the drum 300.

Arranged around the periphery of the drum 300 are a number of hammers or tools 350 mounted in a holder 352 (Fig. 15) of the shape indicated and made of a resilient material such as rubber. Each holder 352 extends for substantially the entire length of the drum and carries, suitably spaced apart, 'a number of hammers 350, see Fig. 16.

The aforesaid diaphragm 326 forms the top closure of a pressure chamber 356 communicating by tube 358 with orifices 360 shaped as indicated in Fig. 15 and extending nearly all the way through the resilient holders 352 as indicated in Fig. 16. The orifice 360 in each holder 352 communicates by another section of tubing 358 with the corresponding orifice in the next succeeding holder so that pressure in the chamber 356 created by a downward movement of diaphragm 326 will be communicated to the orifices in all of the holders 352. Because of the resilient construction of the holders, such air pressure causes the orifices to dilate as indicated at 360a in Fig. 15a, thereby forcing the hammers 350 against the metal deposited on the surface of drum 300.

Thus, in operation, when drum 300 is rotated by contact of switch elements 322 and 324, the diaphragm 326 will be in its upward position so that there is a minimum pressure in the chamber 356 and the rubber holders 352 are contracted with hammers 350 clear of the drum and the metal thereon, as indicated in Fig. 15. However, after the drum has thus been advanced, and while it is held stationary, further rotation of pulley 332 depresses the diaphragm thereby creating in chamber 356 sufficient pressure to cause hammers 350 to press firmly against the metal on drum 300, as indicated in Fig. 15a.

In the embodiments of my invention above described the effort has consistently been to avoid any lateral relative movement between the hammer and the deposited metal during contact because of the laminations which I have found resulted therefrom. I shall now describe a further embodiment which employs, in addition to the hammers which so operate, a supplemental pressure applying element that is allowed to dwell against the surface of the deposited metal purposely to provide frictional contact and thereby to form laminations in selected areas. An article made with such laminations is useful for making such articles as heat'exchangers and the like.

Referring to Figs. 19 to 29, inclusive, I have shown a dual-mandrel, tube-manufacturing machine similar to the machine of Figs. 1 to 12, inclusive, except as will appear.

Suitably mounted on opposite sides of the working tank 2' are electromagnets 400 and 402 (Fig. 20a) one for each of the mandrels i. Pivoted to the side wall of the tank in position to be acted on by each of these electromagnets is a bell crank 404 (Fig. 26) one arm of which carries an etched glass roller 406 and the other arm of which, shown retracted by spring 408, is adapted to be attracted by magnet 402 to press the glass roller 406 against the metal on the surface of the mandrel The electromagnets 400 and 402 are energized simultaneously from a power source 4") (Fig. 21) by parallel identical circuits, typically illustrated by wire 4l4 leading to magnet 400 and by wire 418 leading to pattern cylinder 420 adapted at 12 times to make contact with one of a series of points 422 on rod 426 connected by lead 416 back to each magnet.

Cylinder 420, as shown by a comparison of Figs. 21, 20 and 27 is cut away in parallel recesses 430 extending circumferentially all the way around the cylinder except as interrupted by area 42! on the side of the cylinder seen in Fig. 21 and an identical area, not seen, on the opposite side. These areas, together with the areas 423 between recesses, constitute, in the aggregate, what I shall call thecontacting area of the cylinder and the recesses constitute the non-contacting area.

A pattern cylinder thus formed is mounted on the end of each mandrel l0 and is adapted to rotate and to be advanced and retracted therewith.

As each mandrel with its pattern cylinder advances from its retracted position shown in dotted line in Fig. 21, its contacting areas electrically close circuit with the first point 422 and this circuit is maintained until the cylinder passes that point, except as it is interrupted by the non-contasting areas. The space separating successive contact points is, in the embodiment illustrated, slightly greater than the length of the pattern cylinder.

In practice I have found that in the areas of the deposited metal contacted by the glass roller fine metal particles are ground off the surface and then immediately mechanically redeposited, the deposit being of very minute particles analogous to the deposit of graphite particles made when a pencil marks a sheet of paper. Indeed, as an alternative, I could employ a graphite pencil rubbing against the cathode to produce the same surface deposit. In enlarged scale I have shown this action diagrammatically in Figs. 11:1:, 11:1}, and 112: wherein is indicated how laminations are formed in the metal structure. As I have stated, a small quantity of electrolyte becomes entrapped between such laminations so that when the tubing is thereafter heat-treated the laminated areas expand from the vapor pressure of such electrolyte. Thus, in Fig. 22 the glass roller 405 is shown contacting the surface layer 500 of metal that has been deposited during the advancing movement of the mandrel from the time it entered the tank until it arrived opposite the roller 406. Thereafter, following the contacting, the surface of the metal thus contacted advances with the mandrel beyond the reach of the roller 406 and during its progress from the roller to the end of the tank, a further annular layer of metal l is added to the layer 500. Assuming that, in the operation of Fig. 22, the engagement of the roller occurred as the result of a contact point in the position of 42211. of Fig. 21 wherein it makes electrical contact v recess 430, a lamination 502 will be formed on one side of the cylinder and a corresponding lamina tion 504 will be formed on the opposite side. After electrodeposition is completed and the cylinder is removed, it is then heat-treated and the entrapped moisture causes expansion of the laminated areas as illustrated in Fig. 24 to produce pockets H0 and M2 bounded on the inside by the metal 500 deposited prior to the action of the roller and on the outside by the metal 50! deposited after the lamination was formed.

Using a pattern cylinder of the configuration shown, a chambered tubing of the sort illustrated in Figs. 28 and 29 would be formed having channels 520 resulting from contact with the areas 4230f the pattern cylinder, connected portions 

